Power connector with integrated status monitoring

ABSTRACT

An electrical power system including an electrical power connector, a contact configured to electrically connect a power supply to a load, a first sensor configured to sense a first characteristic of the electrical power connector, a second sensor configured to sense a second characteristic of the electrical power connector, and an electronic controller. The electronic controller configured to receive the first and the second characteristics, analyze the first and second characteristics, and determine an abnormal condition based on the analysis.

RELATED APPLICATIONS

This application claims the benefit to U.S. Provisional PatentApplication No. 62/544,097, filed on Aug. 11, 2017, which claims thebenefit to U.S. Provisional Patent Application No. 62/512,479, filed onMay 30, 2017, the entire contents of both which are incorporated hereinby reference.

FIELD

Embodiments relate to electrical power connectors.

SUMMARY

Electrical power connectors provide a connection between a power supplyand a load. Such electrical power connectors may be described in U.S.patent application Ser. No. 15/072,672, filed Mar. 17, 2016, which ishereby incorporated by reference.

Power measurements can be used to monitor the power consumption of theequipment connected through an electrical power connector. In somecases, the ability to accurately measure the power consumption enablesan operator to allocate energy costs to various users based on the usageof the equipment.

Internal and environmental monitoring, in particular temperature,current, and voltage, may be used to identify normal versus abnormaloperating conditions. Continuous measurement enables identification ofchanges in operating parameters that are out of acceptable ranges sothat an alert is triggered to notify the operators to the condition.Furthermore, data analytics and understanding the normal operatingparameters help provide the user with predictive, or preventive, alertsbefore a potential failure occurs due to environmental, installation, orinternal hardware anomalies.

Other aspects of the application will become apparent by considerationof the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of an electrical power system according to oneembodiment of the application.

FIG. 2 is a perspective view of an electrical power connector of thepower system of FIG. 1 according to some embodiments of the application.

FIG. 3A is a break away view of a contact carrier of the electricalpower connector of FIG. 2 according to some embodiments of theapplication.

FIG. 3B is a break away view of a contact carrier of the electricalpower connector of FIG. 2 according to some embodiments of theapplication.

FIG. 4 is a top view of a transformer winding according to anotherembodiment of the application.

FIG. 5 is a top view of a contact carrier including the transformer ofFIG. 4 according to an embodiment of the application.

FIG. 6 is a block diagram illustrating the logic applicable to the powersystem of FIG. 1.

FIG. 7A is a graph illustrating a voltage parameter and parameterthresholds of the power system of FIG. 1.

FIG. 7B is a graph illustrating a current parameter and parameterthresholds of the power system of FIG. 1.

FIG. 7C is a graph illustrating a temperature parameter and parameterthresholds of the power system of FIG. 1.

DETAILED DESCRIPTION

Before any embodiments of the application are explained in detail, it isto be understood that the application is not limited in its applicationto the details of construction and the arrangement of components setforth in the following description or illustrated in the followingdrawings. For ease of description, some or all of the example systemspresented herein are illustrated with a single exemplar of each of itscomponent parts. Some examples may not describe or illustrate allcomponents of the systems. Other exemplary embodiments may include moreor fewer of each of the illustrated components, may combine somecomponents, or may include additional or alternative components. Theapplication is capable of other embodiments and of being practiced or ofbeing carried out in various ways.

It should be understood that although the example system described is anelectrical connector system, the application may be applied to othersystems including electrical connections. For example, also illustratedas a pin and sleeve device, in other embodiments, the power system mayinclude switches, disconnects, or other wiring devices.

FIG. 1 illustrates an electrical power system 100 according to someembodiments of the application. The power system 100 includes a powersupply 105, a load 110, an electrical power connector, or connector,115, and a power supply cable 120. In some embodiments, the power supply105 is a single-phase power supply outputting a voltage within a rangeof approximately 100 VAC to approximately 240 VAC. In other embodiments,the power supply 105 is a three-phase power supply outputting a voltagewithin a range of approximately 208 VAC to approximately 600 VAC. Insome embodiments, the power supply 105 is a direct-current power supplyoutputting a voltage within a range of approximately 350 VDC toapproximately 450 VDC. In other embodiments, the power supply 105 is adirect-current power supply outputting a voltage within a range ofapproximately 44 VDC to approximately 60 VDC (for example, 48 VDC). Inyet another embodiment, the power supply 105 is a direct-current powersupply outputting a voltage within a range of approximately 15 VDC toapproximately 30 VDC (for example, 48 VDC). The load 110 may be anyelectrical device or system configured to receive power.

FIG. 2 illustrates the connector 115 according to an embodiment of theapplication. The electrical power connector 115 is configured to providean electrical connection between the power supply 105 and the load 110.The connector 115 may be configured to handle twenty-amps, thirty-amps,sixty-amps, one-hundred amps, etc. As illustrated, the connector 115includes a contact carrier 200 and a sleeve connector 205. The contactcarrier 200 includes one or more power terminals 210 located on a firstend 215 of the contact carrier 200. Although not illustrated, thecontact carrier 200 may further include one or more second powerterminals located on a second end 220 of the contact carrier 200.Although illustrated as having four power terminals 210, the connector115 may include any number of power terminals and second power terminals(for example one power terminal and one second power terminal, two powerterminals and two second power terminals, three power terminals andthree second power terminals, four power terminals and four second powerterminals, five power terminals and five second power terminals, etc).In some embodiments, the power terminals 210 are electrically connectedto the load 110 while the second power terminals are electricallyconnected to the power supply 105.

FIGS. 3A & 3B illustrate the contact carrier 200 according to variousembodiments of the application. As illustrated, the contact carrier 200includes a shell 300, a cover 305, one or more contact transformer (CT)modules 400, one or more sensors 325, an electronic controller 335, andan antenna 330. The CT modules 400 each include one or more connectorcontacts 310 and one or more contact cores 315. The shell 300 is formedof a non-conductive material, such as but not limited to, a plasticmaterial. The cover 305 is also formed of a nonconductive material, suchas but not limited to, a plastic material. The shell 300, in conjunctionwith the cover 305, houses various components of the contact carrier200. The one or more connector contacts 310 provide an electricalconnection between the power terminals 210 and the second powerterminals. The contact cores 315 are configured to receive therespective connector contacts 310. The contact cores 315 includetransformer windings 320 integrated into the contact cores 315. Thetransformer windings 320 sense current travelling through the respectiveconnector contacts 310. As illustrated in FIGS. 4 & 5, in someembodiments, the transformer windings 320 have a substantially toroidalshape. In some embodiments, a three-phase power supply may be monitoredusing two sets of transformer windings 320.

In some embodiments, the electronic controller 335 includes anelectronic processor and a memory (not shown). The electronic processorobtains and provides information (for example, from the memory, thesensors 325, and/or the antenna 330), and processes the information by,for example, executing one or more software instructions or modules,capable of being stored, in the memory or another non-transitorycomputer readable medium (not shown). The software can include firmware,one or more applications, program data, filters, rules, one or moreprogram modules, and other executable instructions. In some embodiments,the electronic controller 335 may further include a user interface (notshown). The user interface may receive input from, for example, a userof the connector 115, provides system output, or a combination of both.System output may be provided via audio and/or visual feedback. Forexample, the connector 115 may include a display as part of the userinterface. The display may be a suitable display, for example, a liquidcrystal display (LCD) touch screen, or an organic light-emitting diode(OLED) touch screen. Alternative embodiments may include other outputmechanisms such as, for example, light sources (not shown). Input may beprovided via, for example, a keypad, soft keys, icons, or soft buttonson the display, a scroll ball, buttons, and the like. The user interfacemay include a graphical user interface (GUI) (for example, generated bythe electronic processor, from instructions and data stored in thememory, and presented on the display) that enables a user to interactwith the connector 115. In some embodiments, the connector 115 mayutilize a user interface of an external communication device and/or theload 110 to receive input and provide information. In yet otherembodiments, the user may provide and/or receive input/output with theconnector 115 via an external device (for example, a smartphone, atablet, etc.).

In some embodiments, one or more of the sensors 325 are temperaturesensors configured to sense temperatures central to the core of theconnector 115. In some embodiments, the sensors 325 may sense thetemperature of one or more points of the contact carrier 200. Forexample, such sensors may be positioned at multiple connection pointsand terminals within the connector 115 and configured to senseindividual temperatures of particular terminals. Such sensors may alsoinclude an ambient temperature sensor for sensing a temperature externalthe contact carrier 200 and/or external to the connector 115. Such asensor may be located inside or external to the connector 115. In someembodiments, the sensors 325 include thermistors, thermocouples,resistance temperature detector (RTDs), or any similar sensor. In someembodiments, the sensors 325 include one or more humidity and/ormoisture sensors. In some embodiments, the one or more sensors 325 areconfigured to sense an electrical characteristic of the power system100. For example, such sensors may be configured to sense the voltagebetween the power supply 105 and the load 110 and/or a temperature ofthe contact 310. In some embodiments, one or more of the sensors 325 arepositioned outside of the connector 115.

In the illustrated embodiment, the antenna 330 is routed from theelectronic controller 335 along the outside wall of the shell 300. Insuch an embodiment, the antenna 330 may be disposed inside the shell 300and/or outside the shell 300. In some embodiments, the antenna 330 maybe held in place by one or more slots in support ribs and/or holesadjacent the outside wall. The antenna 330 may be a dipole-type antenna,a loop-type antenna, a flat chip antenna, or any other known antenna.The antenna 330 is configured to wirelessly transmit variouscharacteristics of the connector 115. For example, the antenna 330 maywirelessly transmit current, voltage, and temperature measurements fromone or more sensors 325 within the connector 115. In some embodiments,the characteristics are wirelessly transmitted to one or more externaldevices. Such external devices may include the load device 110, acommunication device (i.e. a phone, a tablet, a computer), a wiringdevice, and/or a remote server/database or cloud network. In someembodiments, rather than, or in addition to, antenna 330, the contactcarrier 200 may include an input/output port. In such an embodiment, thevarious characteristics described above may be transmitted via physicalcoupling (for example, a wired connection). In some embodiments, theelectronic controller 335 is partially (i.e. some of the components ofthe electronic controller 335) located within the connector 115 andpartially located on at least one selected from the group consisting ofan external communication device, an external wiring device, a remoteserver, and a cloud network.

The memory can include random access memory (RAM), read only memory(ROM), or one or more other non-transitory computer-readable media, andmay include a program storage area and a data storage area. The programstorage area and the data storage area can include combinations ofdifferent types of memory, as described herein. In one embodiment, theelectronic processor of the electronic controller 335 is configured toretrieve from the memory and execute, among other things, softwarerelated to control processes, for example, the methods described herein.For example, as described more particularly below with respect to FIG.4, the electronic controller 335 (in particular, the electronicprocessor) may be fully configured to determine a status of a loaddevice based on one or more environmental or operational inputs. In someembodiments, the electronic controller 335 may be configured to provideinformation to an external device and/or remote server/database so thatthe external device and/or remote server/database may determine a statusof a load device based on one or more environmental or operationalinputs.

FIG. 3B illustrates the contact carrier 200 according to anotherembodiment. Such an embodiment further includes an insulating sleeve 311and a spacer 312. The insulating sleeve 311 is configured to receive theone or more connector contacts 310.

FIG. 4 illustrates biased transformer windings 320 according to anotherembodiment of the application. As illustrated in FIG. 5, the biasedtransformer windings 320 may be integrated into, or around, CT modules400. In such an embodiment, the biased transformer windings 320 may be aRagowski helical coil or a biased winding toroid. Such an embodiment mayenable the placement of the CT modules 400 into geometries that aretypically too small for a full transformer winding. Such an embodimentmay enable more accurate current readings.

FIG. 6 is a process block diagram 600 illustrating a diagnostic analysislogic unit 602 applicable to the power system 100 of FIG. 1. For ease ofdescription, FIG. 6 includes both functions which may be implemented inhardware and/or software and hardware components of the power system100. In one embodiment, some or all of the functions of the diagnosticanalysis logic unit 602 are implemented by the electronic processor ofthe electronic controller 335 (using software, hardware, or acombination of both). In further embodiments, some or all of thefunctions of the diagnostic analysis logic unit 602 are implemented byan external communication device, an external wiring device, and/or aremote server/database external to the power system 100. For example,the electronic processor may transmit the measurements of the sensors325 to the one or more of the external communication device, theexternal wiring device, and/or the remote server/database or cloudnetwork to be processed further. In some embodiments, some or all of thefunctions of the diagnostic analysis logic unit 602 are implemented on auser interface (for example, a graphic user interface).

The diagnostic analysis logic unit 602 is configured to receive data andinformation from a variety of sources including, for example, thesensors 325, the antenna 330, and the electronic processor. Thediagnostic analysis logic unit 602 may also receive information(including, as described below, installation condition information 604,measured/calculated parameters 606, and parameter threshold information608) from one or more of the load 110, the power supply 105, an externalcommunication device, an external wiring device, and/or a remoteserver/database or cloud network. The data and information receivedrelates to the operation of the power system 100. For example, asillustrated in FIG. 6, the diagnostic analysis logic unit 602 receivesapplication and installation condition information 604 of the powersystem 100, measured/calculated parameters 606, and parameter thresholdinformation 608 from the load 110, the sensors 325, the antenna 330,and/or the power supply 105. It should be understood that other kinds ofdata and information relating to the operation of the power system 100may also be received. As explained in more detail below, the diagnosticanalysis logic unit 602 is configured to process the data andinformation received to monitor the operation of the power system 100and to detect one or more abnormalities in the system 100.

It should be understood that although the processes performed by thediagnostic analysis logic unit 602 are described herein as static logic,in some embodiments the diagnostic analysis logic unit 602 may beconfigured to perform one or more machine-learning or artificialintelligence process algorithms to perform or improve prediction ordiagnostic capability based on the information received from the load110 and/or connector 115. In such embodiments, the diagnostic analysislogic unit 602 may be configured to utilize predictive monitoring anddiagnostic analysis in order to predict one or more of a potentialabnormality.

The installation condition information 604 relates to expected ambientconditions such as an expected/allowed temperature range, an indoorversus outdoor use, a degree of climate control or non-climate control,a level of moisture/humidity, a natural temperature variation, ageographical location, and an installation location to derive parameterthresholds (described more particularly below) and anticipated cycles ofoperation.

For example, an installation in a non-climate controlled location mayallow cold temperatures of operation. Installations in such conditionsmay not rely solely on maximum measured temperature to determine normaloperation and identify potential issues such as poor terminations orconnection issues. For example, the connector 115 may operate in anambient temperature of approximately −20° C. and a terminal temperatureof the connector 115 may be measured at approximately 20° C., such a 40°temperature rise may suggest an abnormal condition within the connector115 or somewhere in the power system 100. Another example would be theconnector 115 installed in a climate where the temperature may vary fromapproximately 10° C. to approximately 50° C. throughout the course of aday. In such cases, the system 100 may be configured to allow for thecyclical temperature swings, while also monitoring for abnormalconditions. The ambient temperature/climate conditions may be inferredfrom the sensors 325 internal or external to the connector 115 and/orreceived from a remote ambient sensor or external communication device.In some embodiments, the diagnostic analysis logic unit 602 isconfigured to learn the thermal environment in which the connector 115is installed using one or more machine learning/artificial intelligenceprocesses.

In some embodiments, information relating to operational requirementsand acceptable operating ranges of the power system 100 and/or load 110may be representative of the type of installation, such as aninstallation in an industrial facility or data center. Theidentification of the installation allows for certain parameter defaultvalues/predetermined thresholds that can serve as the startingconfiguration as opposed to a user individually setting each parameter.For example, in an industrial setting where the connector 115 isproviding power to multi-phase, balanced industrial machines, thecurrents and voltages of each machine may be anticipated to be the same.When providing power for a data center however, the phases of thecurrent and the voltage may be anticipated to be unbalanced depending onthe load on each phase. The default configuration may further beadjusted based on additional information and/or user input. Suchinformation regarding operating ranges and parameters may be receivedfrom the load 110, an external communication device or server, orreceived directly via a user input through a graphical interface incommunication with the logic unit 602.

The measured/calculated parameters 606 may include data received and/orderived from values from one or more of the sensors 325. Themeasured/calculated parameters 606 include one or more electrical and/orthermal characteristics within the power system 100. For example, thesensors 325 may be configured to measure electrical and/or thermalcharacteristics at the input and output sides of each contact (forexample contacts 310) or at other electrical connections within theconnector 115. In some embodiments, the sensors 325 may be configured tomeasure characteristics at the power supply 105 and power terminals 210.In further embodiments, the measured/calculated parameters 606 mayinclude humidity characteristics.

Electrical characteristic measurements and calculated values are used bythe diagnostic analysis logic unit 602 to identify abnormal operatingconditions within other types of devices (for example, a welded contactor stuck switch when phase voltages and currents do not behave asexpected). For example, if a switch is expected to be open, then thecurrent and a voltage on one side of the electrical connection may beexpected to be approximately zero. The presence of voltage on the loadside of the electrical connection or the flow of current may beindicative of a closed contact. Alternatively, the diagnostic analysislogic unit 602 uses the multiple voltage measurement points from thesensors 325 in combination with current level to identify highresistance conditions, which may be indicative of poor connections. Theelectrical characteristic information may also be used to identify andconfirm a proper coupling sequence of components within the connector115. For example, if a switch is expected to be closed, then voltage andcurrent is expected. If no voltage and/or current is sensed, an impropercoupling may be present.

In some embodiments, the measured/calculated parameters 606 are used bythe diagnostic analysis logic unit 602 to identify a proper order ofconnections/disconnections within the power system 100. In some cases,certain connections within the connector 115 may require a connection toan electric ground (or power) before being connected. For example, adata connection within the electronic controller 335 may be required tobe connected after one or more power connections of the electroniccontroller 335 are connected. Based on the measured/calculatedparameters 606, the diagnostic analysis logic unit 602 may be able todetermine whether the one or more power connections are connected (andtheir order of connection) before the data connection is made anddetermine an abnormal condition if the connections were doneinappropriately. Likewise, the order of disconnection may be evaluatedto determine an appropriate disconnection within the power system 100.

The diagnostic analysis logic unit 602 may also use temperaturemeasurements to monitor and identify an abnormal condition within thepower system 100. For example, the diagnostic analysis logic unit 602may receive data from the sensors 325 regarding the temperature of eachof the connection points (or line inputs) within the connector 115. Fromthis data, the diagnostic analysis logic unit 602 may identifyoperation-related variations of the installation environment of thepower system 100. As opposed to a single point measurement, the multiplepoint measurement method implemented using the sensors 325 allows thediagnostic analysis logic unit 602 to distinguish operational conditionsfrom fault conditions. For example, when the power supply 105 and/orconnector 115 is three-phase, if the temperatures of both the firstphase and second phase contacts 310 within the connector 115 aremeasured to be approximately equal, or are within a predetermined rangeof each other, then the ambient temperature may be approximately equalor lower than these temperatures. Accordingly, if the temperature of thethird phase contact 310 within the connector 115 differs from thetemperatures of the first and second contacts 310 (outside thepredetermined range), the difference may be a temperature riseindicative of a possible abnormal condition. The abnormal conditioncould be, for example, a loose wire termination. The diagnostic analysislogic unit 602 accordingly identifies which of the phase contacts 310has the abnormal condition based on the data from the sensors 325.

In some embodiments, the diagnostic analysis logic unit 602 isconfigured to calculate an effective environmental temperature. In someembodiments, the effective environmental temperature, or minimumpredicted operational, is the effective temperature in the environmentsurrounding the contact carrier 200. The diagnostic analysis logic unit602 calculates the effective environmental temperature based on at leastdata from the sensors 325. The diagnostic analysis logic unit 602 maycalculate the effective environmental temperature by using present andpreviously obtained electrical and temperature measurements from theother sensors 325 at various points within the connector 115. Theeffective environmental temperature may be used to determine anabnormality within the connector 115.

For example, in some embodiments the diagnostic analysis logic unit 602collects a series of current measurements from each of the sensors 325corresponding to one or more of the contacts 310 over time to develop atemperature rise curve for the contacts 310 and the connector 115. Thediagnostic analysis logic unit 602 then identifies the contact 310 withthe lowest measured temperature. The diagnostic analysis logic unit 602then calculates the expected temperature rise for the lowest current.Under normal conditions, for an unbalanced system, the contact 310 withthe lowest current may be the coolest. When the contact 310 with thelowest current does not exhibit the lowest measured temperature of thecontacts 310 within a predetermined error threshold, an abnormality maybe present.

The diagnostic analysis logic unit 602 calculates theeffective/predicted environmental temperature by subtracting theexpected temperature rise from the measured temperature. The diagnosticanalysis logic unit 602 may also calculate the temperature deviation foreach measured temperature for each contact 310 from theeffective/predicted environmental temperature by comparing thetemperature rise for each contact 310 to the expected temperature risegiven the current. When the temperature rise for one or more of thecontacts 310 does not fall within a predetermined range of the expectedtemperature rise given the current, an abnormality may be present.

An abnormal condition may be further diagnosed based on the additionalinformation provided to diagnostic analysis logic unit 602. For example,if the temperatures of each of the contacts 310 are different, thediagnostic analysis logic unit 602 may examine/analyze their currentvalues received from the sensors 325 to determine if the difference intheir temperatures is abnormal. If the current within each of thecontacts 310 are the same, a difference in temperature may indicate anabnormal condition. However, if the current within of each of thecontacts 310 are different, a limited or predetermined difference intemperature may be expected during normal operation. The diagnosticanalysis logic unit 602 may further identify the location of and/orcomponents relative to the abnormal condition based on the information.

The parameter threshold information 608 includes parameter thresholdsthat are used by the diagnostic analysis logic unit 602 to compare themeasured parameters 606 to determine the operation status and conditionsof the power system 100. Each parameter threshold corresponds to adesired parameter at a particular connection point and/or terminalwithin the connector 115. FIGS. 7A-7C each illustrate various parametersover time series of voltage, current, and temperature parameterthresholds respectively.

In some embodiments, the parameter thresholds may be fixed values. Forexample, a parameter threshold may be a maximum threshold (for example,708) or a minimum threshold (for example, 710). A parameter thresholdmay be based on material properties (for example, absolute current ortemperature material limit 720 and 734 respectively), material orproduct ratings (for example, maximum rated threshold 721), orapplication constraints (for example, application limit 724). Aparameter threshold may also be based on a series of parameter datapoints indicative of a known operational behavior of the connectorsystem. For example, the known operational behavior may be theanticipated temperature rise (or lack thereof) per amp of current orrate of change in temperature given a change in current. This knownoperational behavior may be stored in the memory or retrieved from aremote server/database or cloud network. Other parameter thresholds maybe set at the time of manufacture based on calibration or configurationor at installation. When set at the time of installation, theseparameter thresholds in some embodiments may be configured by a user. Insome embodiments, the diagnostic analysis logic unit 602 may receive auser input via the user interface (for example, included in the load110, the connector 115, and/or an external communication device)specifying a default parameter value/predetermined threshold or a customparameter threshold setting. In such embodiments, the user input may bea predetermined parameter threshold profile, specifying a set ofparameter thresholds for a particular application and/or environment.For example, the predetermined limit threshold profile adjusts theparameter thresholds based on the application, type of load (balanced orunbalanced), and installation setting (climate/temperature).

In some embodiments, the parameter thresholds are dynamically adjustedbased on the measured/calculated parameters 606. The parameterthresholds may be adjusted depending on ambient temperature, currentlevels, operational cycle or historic data, or other parameters. Byadjusting to the measured conditions and known parameters, and by beingable to set these limits independently for each connection point, thediagnostic analysis logic unit 602 is able to determine an exactlocation of an abnormal condition and avoid false positive alerts.

When a condition is suspect based on the initial setup, the diagnosticanalysis logic unit 602 may notify the user of the condition and providean option for the user to flag the condition as acceptable under certainconditions—such as a higher absolute temperature if the ambienttemperature increases substantially. Another example of a conditionwhich needs normalization when the connector 115 is oriented in such away that one of the connections is closer to an external heat source.This connection will permanently show a higher temperature. Accordingly,the user may choose to accept this as a “normal” condition.

In some embodiments, the diagnostic analysis logic unit 602 isconfigured to learn or normalize operational limits. The diagnosticanalysis logic unit 602 may learn operational limits by, for example,implementing one or more machine learning/artificial intelligenceprocesses. In such embodiments, the diagnostic analysis logic unit 602may use machine learning or artificial intelligence in addition to or inlieu of user input. For example, the diagnostic analysis logic unit 602may automatically determine whether a condition is acceptable or notwithout providing an option to the user.

FIGS. 7A-7C illustrate parameter graphs including possible parameterthresholds. It should be understood additional thresholds may beconsidered for each parameter. FIG. 7A illustrates a voltage over timegraph 700. The graph 700 illustrates a first phase voltage 702, a secondphase voltage 704, and a third phase voltage 706 measured within theconnector 115. The graph 700 illustrates a maximum voltage threshold 708and a minimum voltage threshold 710.

FIG. 7B illustrates a current over time graph 712. The graph 712illustrates a first phase current 714, a second phase current 716, and athird phase current 718 measured within the connector 115. The averagecurrent 719 is also measured or calculated. The graph 712 illustrates anabsolute material limit 720, a maximum rated current threshold 721, anda maximum current difference threshold 722. These parameter thresholdsmay be based on the material and application limitations and applicationof the connector 115 and/or load device 110. In some embodiments,similar parameter thresholds may be used with respect to voltage (FIG.7A) The graph 712 also illustrates an application limit 724 which may bea custom parameter threshold defined by a user.

FIG. 7C illustrates a temperature over time graph 726. The graph 726illustrates a first phase contact temperature 728, a second phasecontact temperature 730, and a third phase contact temperature 732measured within the connector 115. The average temperature 733 is alsomeasured or calculated. The graph 726 illustrates an absolute materiallimit 734, a maximum difference in temperature limit 735, and atemperature increase rate threshold 736 (based on the applicationlimitations). The graph 726 also includes a custom user selectedapplication temperature increase rate threshold 737.

Returning to FIG. 6, the diagnostic analysis logic unit 602 isconfigured to determine, based on an analysis of one or more of theinputs received, an operation status of the power system 100. Forexample, the state of the connector 115, the load 110, the power supply105, and the connections between are evaluated/analyzed to determine theoperational status of the power system 100. The operational status maybe normal if no abnormal conditions have been determined. Theoperational status may be abnormal is at least one abnormal condition isdetermined. The connector 115 is configured to adaptively provide powerto a variety of loads and types of equipment. For example, when theconnector 115 is serving multi-phase, balanced industrial machines, thecurrents and voltages are expected to be the similar in magnitude, sothe system will react differently to variations in power and currentthrough the connector 115 compared to serving a power strip in a datacenter where the phases are expected to be unbalanced depending on theload on each phase.

In some embodiments, the diagnostic analysis logic unit 602 is furtherconfigured to determine an operation status of the power system 100based on information received from the load device 110. For example, ifthe load device 110 provides its own measured electricalcharacteristics, the diagnostic analysis logic unit 602 compares thereceived electrical characteristics to the corresponding electricalcharacteristics within the measured/calculated parameters 606 toidentify a possible abnormal condition (for example, a power lossbetween the connector 115 and load device 110). In further embodiments,the results of the comparison may be used with machine learning andartificial intelligence algorithms to further improve predictioncapability of machine or process deviation or failure.

The diagnostic analysis logic unit 602 may then generate, based on thestatus, a status indication 610. The status indication 610 is at leastone selected from the group consisting of an audible, visual, and hapticsignal. The indication may be presented by a visual signal forpresentation on a display of a communication device, an audio signal, oran error signal for recordation in a log in the communication device ora remote server/database. In some embodiments, the electronic processoris further configured to send the error signal to an error log stored ineither a local memory, for example the memory, or a remote server and/ordatabase.

In some embodiments the diagnostic analysis logic unit 602 is configuredto determine a degree of the operational status based on a comparisonbetween the measured/calculated parameters 606 and the correspondingparameter threshold and generate a particular type of indication basedon a severity of the abnormal condition. For example, depending on theseverity of the abnormal condition, the diagnostic analysis logic unit602 may generate a notification, alert, or an alarm.

In some embodiments, the diagnostic analysis logic unit 602 furtherincludes a maintenance schedule tracker. The maintenance scheduletracker is configured to provide reminders via the user interface andrecord maintenance events in the memory and/or the remoteserver/database. The maintenance schedule may be defined by a user, forexample via the user interface, or a default/predetermined scheduledefined based on the application and/or environment of the power system100. The maintenance schedule may further be dynamically adjusted by thediagnostic analysis logic unit 602 based on the installation conditioninformation 604, the measured/calculated parameters 606, the parameterthreshold information 608 and/or other operating conditions within thepower system 100.

Thus, the application provides, among other things, an improved methodand system for sensing various characteristics of an electronic powerconnector. In the foregoing specification, specific embodiments havebeen described. However, one of ordinary skill in the art appreciatesthat various modifications and changes can be made without departingfrom the scope of the invention as set forth in the claims below.Accordingly, the specification and figures are to be regarded in anillustrative rather than a restrictive sense, and all such modificationsare intended to be included within the scope of present teachings.

The benefits, advantages, solutions to problems, and any element(s) thatmay cause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeatures or elements of any or all the claims. The invention is definedsolely by the appended claims including any amendments made during thependency of this application and all equivalents of those claims asissued.

Moreover in this document, relational terms such as first and second,top and bottom, and the like may be used solely to distinguish oneentity or action from another entity or action without necessarilyrequiring or implying any actual such relationship or order between suchentities or actions. The terms “comprises,” “comprising,” “has,”“having,” “includes,” “including,” “contains,” “containing” or any othervariation thereof, are intended to cover a non-exclusive inclusion, suchthat a process, method, article, or apparatus that comprises, has,includes, contains a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus. An element proceeded by“comprises . . . a,” “has . . . a,” “includes . . . a,” or “contains . .. a” does not, without more constraints, preclude the existence ofadditional identical elements in the process, method, article, orapparatus that comprises, has, includes, contains the element. The terms“a” and “an” are defined as one or more unless explicitly statedotherwise herein. The terms “substantially,” “essentially,”“approximately,” “about” or any other version thereof, are defined asbeing close to as understood by one of ordinary skill in the art, and inone non-limiting embodiment the term is defined to be within 20%, inanother embodiment within 10%, in another embodiment within 2% and inanother embodiment within 1%. The term “coupled” as used herein isdefined as connected, although not necessarily directly and notnecessarily mechanically. A device or structure that is “configured” ina certain way is configured in at least that way, but may also beconfigured in ways that are not listed.

It will be appreciated that some embodiments may be comprised of one ormore generic or specialized processors (or “processing devices”) such asmicroprocessors, digital signal processors, customized processors andfield programmable gate arrays (FPGAs) and unique stored programinstructions (including both software and firmware) that control the oneor more processors to implement, in conjunction with certainnon-processor circuits, some, most, or all of the functions of themethod and/or apparatus described herein. Alternatively, some or allfunctions could be implemented by a state machine that has no storedprogram instructions, or in one or more application specific integratedcircuits (ASICs), in which each function or some combinations of certainof the functions are implemented as custom logic. Of course, acombination of the two approaches could be used.

Moreover, an embodiment can be implemented as a computer-readablestorage medium having computer readable code stored thereon forprogramming a computer (e.g., comprising a processor) to perform amethod as described and claimed herein. Examples of suchcomputer-readable storage mediums include, but are not limited to, ahard disk, a CD-ROM, an optical storage device, a magnetic storagedevice, a ROM (Read Only Memory), a PROM (Programmable Read OnlyMemory), an EPROM (Erasable Programmable Read Only Memory), an EEPROM(Electrically Erasable Programmable Read Only Memory) and a Flashmemory. Further, it is expected that one of ordinary skill,notwithstanding possibly significant effort and many design choicesmotivated by, for example, available time, current technology, andeconomic considerations, when guided by the concepts and principlesdisclosed herein will be readily capable of generating such softwareinstructions and programs and ICs with minimal experimentation.

The Abstract of the Disclosure is provided to allow the reader toquickly ascertain the nature of the technical disclosure. It issubmitted with the understanding that it will not be used to interpretor limit the scope or meaning of the claims. In addition, in theforegoing Detailed Description, it can be seen that various features aregrouped together in various embodiments for the purpose of streamliningthe disclosure. This method of disclosure is not to be interpreted asreflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter lies in less than allfeatures of a single disclosed embodiment. Thus the following claims arehereby incorporated into the Detailed Description, with each claimstanding on its own as a separately claimed subject matter.

The invention claimed is:
 1. An electrical power system comprising: an electrical power connector; a contact transformer module including a contact and a contact core, wherein the contact is configured to electrically connect a power supply to a load, and the contact core is configured to receive the contact; at least one toroidal transformer winding integrated into the contact core, the at least one toroidal transformer configured to sense a current of the electrical power connector; at least one selected from a group consisting of a temperature sensor configured to sense a temperature of the electrical power connector and a voltage sensor configured to sense a voltage of the electrical power connector; and an electronic controller configured to receive a first signal indicative of the current and a second signal indicative of at least one selected from a group consisting of the temperature and the voltage, compare the first and second signals to one or more thresholds, determine an abnormal condition based on the comparisons, and dynamically adjust the one or more thresholds based on at least one selected from a group consisting of a measured or calculated parameter, an installation condition, an operational limit, a known operational behavior, and parameter threshold information.
 2. The electronic power system of claim 1, wherein the sensed temperature is a temperature of a core of the electrical power connector.
 3. The electronic power system of claim 1, wherein the threshold is a default value based on an application of the electrical power system.
 4. The electronic power system of claim 1, wherein the electronic controller is located within the electrical power connector.
 5. The electronic power system of claim 1, wherein the electronic controller is located on at least one selected from the group consisting of an external communication device, an external wiring device, a remote server, and a cloud network.
 6. The electronic power system of claim 1, wherein the controller is partially located within the electrical connector and partially located on at least one selected from a group consisting of an external communication device, an external wiring device, a remote server, and a cloud network.
 7. The electronic power system of claim 1, wherein at least one of the first signal and the second signal is based on an installation condition.
 8. The electronic power system of claim 7, wherein the installation condition is at least one selected from a group consisting of an expected/allowed temperature range, an indoor versus outdoor use, a degree of climate control or non-climate control, a level of moisture/humidity, a natural temperature variation, a geographical location, and an installation location.
 9. The electrical power system of claim 1, wherein the controller is further configured to provide a maintenance schedule tracker.
 10. The electrical power system of claim 1 further comprising a load, wherein the controller is further configured to determine an abnormal condition of the power system based on information received from the load.
 11. The electrical power system of claim 1, wherein the controller is further configured to utilize machine learning and artificial intelligence algorithms to perform or improve prediction or diagnostic capability based on the information received from at least one selected from the load.
 12. The electrical power system of claim 11, wherein the controller is further configured to utilize machine learning and artificial intelligence algorithms to further improve prediction capability based on the information received from the load.
 13. The electrical power system of claim 1, wherein the abnormal condition is further based on one or more installation conditions and one or more parameter thresholds.
 14. An electrical power system comprising: an electrical power connector configured to receive AC power; a contact carrier including one or more power terminals and a contact transformer module, wherein the contact transformer module includes one or more connector contacts and one or more contact cores, each of the one or more contact cores configured to receive one of the one or more connector contacts; a transformer winding integrated into each of the one or more connector contacts, the transformer winding configured to sense a current traveling through the respective connector contact; and an electronic controller configured to compare the current to a threshold, wherein the electronic controller is further configured to dynamically adjust the threshold based on at least one selected from a group consisting of a measured or calculated parameter, an installation condition, an operational limit, a known operational behavior, and parameter threshold information.
 15. The electrical power system of claim 14, wherein the contact carrier further includes one or more contact transformer modules.
 16. The electrical power system of claim 15, wherein the transformer winding is integrated into the one or more contact transformer modules.
 17. The electrical power system of claim 14, wherein the transformer winding is one selected from the group consisting of a Ragowski helical coil and a biased winding toroid. 